1. Valorisation of agro-industries wastes in papermaking: the CRUSH PROCESS.
TOTAL FOOD 2017
Achille Monegato R&D
Michele Posocco MKT
Flavio Stragliotto Mill Manager
02th Nov. 2017, Norwick UK

2. PAPER PRODUCTION 2016
WORLD 411 million t
ITALY 8,9 million t

3. VIRGIN FIBRE CONSUMPTION IN ITALY (2016)
3.4 million t VIRGIN FIBER CONSUMPTION
0,3 million t PRODUCED IN ITALY
3.1 million t IMPORTED (2 BILLION €)
corncob
paper

4. FAVINI SNAPSHOT 70.000T of the fine papers Turnover 2016: 160M€
30% domestic market, 70% export
High levels of customer satisfaction with respect to product and service quality from:
500 employees
3 paper machines
3 cutting machines
2 air knife coaters
3 cast coaters
10 embossers
Headquarters (Rossano Veneto)

5. FAVINI ORGANISATION 3 divisions:
Graphic Specialties: 2 plants in Italy
Rossano Veneto
Crusinallo
Casting Release: Crusinallo
Converting: Rossano Veneto 5

6. Replacement of virgin cellulose;
CRUSH PROCESS
Favini has developed a technology, called CRUSH PROCESS, which uses by-products from the food and agro industry for paper production.
These materials can be used in the papermaking with the following benefits:
Replacement of virgin cellulose;
Lengthening of the life cycle of the by-product;
These materials are not subtracted from the human food supply chain. 6

7. The CRUSH PROCESS consists of the following four phases:
Research of by-product at the end of generable products of and drying;
Grinding with various systems (micronization because the size of the materials must have a granulometry ranging from 1 to 200 microns);
Screening of ground materials
Use in the paper production (up to 25%). 7

8. CRUSH PROCESS: different residues
Wine (pomace – marc)
Olive (pomace)
Hazelnuts (shell)
Almonds (shell)
Citrus fruits (pomace)
Beans (broken, not suitable for food)
Maize (corncob)
Wheat (external bran)
Cherries (kernel)
Cocoa (shell)
Barley (whiskey, beer)
Coffee (silver skin)
Tomatoes (skin) …. 8

9. EXAMPLES OF BIOMASSES USED FOR PRODUCING CRUSH PAPER
RESIDUES OF WINERY INDUSTRY;
RESIDUES OF CITRUS INDUSTRY;
THE PAPERS CONTAINING THESE
RESIDUES ARE CALLED CRUSH
PAPER

10. RESIDUES OF VINERY INDUSTRY (2016)
WORLD WINE PRODUCTION (2016) 26 million t
WINE PRODUCTION ITALY (2016) 5 million t (19%)
MARC/POMACE WITHOUT ALCOHOL: what remains of grape after wine, distillation and separation of the kernels (which are started at the extraction of the oil).
AMOUNT AVAILABLE IN DISTILLERIES: extimated t/y

11. WINERY INDUSTRY

12. “Veuve Clicquot”: FROM CHAMPAGNE TO PACKAGING

13. CITRUS WASTE (2014) CITRUS WORLD PRODUCTION (2014) 110 million t
CITRUS ITALIAN PRODUCTION (2014) 3,3 million t
(3.0%)
CYTRUS POMACE: peel, pulp and seeds of the industrial processing of juices and essences
AMOUNT AVAILABLE in agro-industrial processes: t/year

14. CITRUS INDUSTRY

15. USES: SHOPPING BAGS with different Crush Papers15

16. USES: FASHION TAGS with corncob residues16

17. USES: PACKAGING FOR BARILLA with not edible bran
Academia Barilla designed a gift box for food lovers that supports environmental sustainability. The packaging is completely made of CartaCrusca by Favini. CartaCrusca is the paper made with bran.

18. CONCLUSIONS 1
The Italian paper industry needs cellulosic fibers: nowdays (2016) we imported 3.1 million tons;
In the Italian agro-industry there are biomasses (by-products) that, suitably modified (dried and micronized), can be used up to 25% in the paper production;
These biomasses are generated through certified, controlled and regulated industrial processes. Usually they are destined for animal feeding, energy production, biogas, soil improvers or landfill;
The paper obtained with these materials is recyclable: it becomes itself part of the ecological message that you want to develop;
There is a cultural barrier that prevents us from seeing in the residues of agro -industrial as raw materials for other sectors in the spirit of the circular economy and industrial symbiosis;
We are not against the use of these biomasses for the production of thermal energy or biogas, but we suggest that, before this, them can used in the papermaking.

19. CONCLUSIONS 2
VALUE GENERATED
The virgin cellulose fiber costs on average 600 €/t. The by-product that comes out of the CRUSH PROCESS must necessarily has a lower cost to make the system economically viable; NETWORK
The need to put together different actors - the residual producer, the transformer, the end user - creates a network of synergies and values between industrial fields, where everyone must have a benefit of knowledge and earnings.

20. Thank you